CN113573864A - Fiber-reinforced resin article, method for producing same, and laminate comprising same - Google Patents

Fiber-reinforced resin article, method for producing same, and laminate comprising same Download PDF

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Publication number
CN113573864A
CN113573864A CN202080021468.2A CN202080021468A CN113573864A CN 113573864 A CN113573864 A CN 113573864A CN 202080021468 A CN202080021468 A CN 202080021468A CN 113573864 A CN113573864 A CN 113573864A
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China
Prior art keywords
reinforced resin
fiber
sheet
uds
unidirectional
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CN202080021468.2A
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Chinese (zh)
Inventor
菊地一明
伊崎健晴
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Mitsui Chemicals Inc
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Mitsui Chemicals Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/14—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a face layer formed of separate pieces of material which are juxtaposed side-by-side
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
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    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
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    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
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Abstract

Disclosed is a fiber-reinforced resin article, which comprises a plurality of unidirectional fiber-reinforced resin sheet (CS)2 that is the same as or different from a unidirectional fiber-reinforced resin sheet (UDS) on at least one side of the unidirectional fiber-reinforced resin sheet (UDS)1, wherein the proportion of the Chopped Sheet (CS) to 100 parts by mass of the unidirectional fiber-reinforced resin sheet (UDS) is 40 to 100 parts by mass; a method for producing a fiber-reinforced resin article, which comprises a step for arranging a plurality of Chopped Sheets (CS)2, and a step for heating and pressing the chopped sheets; and a laminate comprising the fiber-reinforced resin article and a foam layer.

Description

Fiber-reinforced resin article, method for producing same, and laminate comprising same
Technical Field
The present invention relates to a fiber-reinforced resin article having a unique appearance with a marble pattern such as a random sheet and having no defects (holes or the like) even when the thickness is thin, a method for producing the same, and a laminate comprising the same. In particular, the present invention relates to a fiber-reinforced resin article which is very useful for applications such as electric parts, PC cases, cell phone covers, automobile parts, furniture, and wallpaper for building materials.
Background
Conventionally, fiber-reinforced resin articles obtained by compounding reinforcing fibers with a matrix resin have been used in various fields. As such a fiber-reinforced resin article, for example, a unidirectional fiber-reinforced resin sheet, a laminate in which a plurality of unidirectional fiber-reinforced resin sheets are laminated, or a random sheet is known.
Patent document 1 describes a unidirectional fiber-reinforced resin sheet (unidirectional material) using a specific carbon fiber bundle as a reinforcing fiber bundle, a laminate (unidirectional laminate) in which a plurality of unidirectional fiber-reinforced resin sheets are laminated, and a random sheet (random stampable sheet).
The random sheet is a sheet that is generally called a CTT material (chopped carbon fiber tape reinforced thermoplastic) and is isotropic in plane, has a unique appearance of a marble pattern, and is easily given a three-dimensional shape by a molding method such as press molding or press molding. The random sheet can be obtained, for example, by: a plurality of chopped strands obtained by cutting a unidirectional fiber-reinforced resin sheet into small pieces are randomly stacked, and are integrated by press molding.
Patent document 2 describes a structure which is a laminate of a random sheet molded body and a unidirectional sheet molded body, and the random sheet molded body is disposed on at least one surface. Further, it was demonstrated that the structure was excellent in strength, strength anisotropy, moldability and molded appearance.
Documents of the prior art
Non-patent document
Patent document 1: international publication No. 2016/114352
Patent document 2: japanese patent laid-open publication No. 2013-208725
Disclosure of Invention
Problems to be solved by the invention
In recent years, demands for fiber-reinforced resin articles to be thin and lightweight have been increasing. However, since the random sheet is a sheet obtained by stacking and integrating 8 or more layers of chopped strands in order to exhibit in-plane isotropy, the random sheet is considerably thicker than the unidirectional fiber-reinforced resin sheet. In order to make the random sheet thinner, the number of layers of the chopped strands needs to be small, but if the number of layers is extremely small, the following tendency is present: the cut sheets are perforated at the portions where the cut sheets are not laminated to form discontinuous sheets.
The structure described in patent document 2 is a laminate obtained by laminating a random sheet molded body and a unidirectional sheet molded body (unidirectional fiber-reinforced resin sheet), and therefore cannot sufficiently satisfy the above-described requirements for reduction in thickness and weight. This is because the random sheet molded body used in patent document 2 is a molded body obtained by stacking and integrating a plurality of (about 7 to about 9 layers in the example) chopped prepregs (chopped sheets) in a laminated manner, similarly to the above random sheet, and is itself quite thick. Further, since the thick random sheet molded body and the unidirectional sheet molded body are laminated, the total thickness of the structure becomes thicker.
The present invention has been made to solve the above problems. That is, an object of the present invention is to provide a fiber-reinforced resin article having a unique appearance with a marble pattern such as a random sheet and having no defects (holes or the like) even when the thickness is thin, a method for producing the same, and a laminate comprising the same.
Means for solving the problems
The present inventors have conducted intensive studies to solve the above problems, and as a result, have found that it is very effective to integrate chopped strands into at least one surface of a unidirectional fiber-reinforced resin sheet, and have completed the present invention. That is, the present invention is particularly defined by the following matters.
[1] A fiber-reinforced resin article comprising a plurality of unidirectional fiber-reinforced resin sheets (CS) that are the same as or different from unidirectional fiber-reinforced resin sheets (UDS) on at least one side of the unidirectional fiber-reinforced resin sheets (UDS),
the proportion of the chopped strand sheet (CS) is 40 to 100 parts by mass with respect to 100 parts by mass of the unidirectional fiber-reinforced resin sheet (UDS).
[2] The fiber-reinforced resin article according to [1], wherein the unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS) comprise a thermoplastic resin.
[3] The fiber-reinforced resin article according to [2], wherein the thermoplastic resin is at least one thermoplastic resin selected from the group consisting of polypropylene-based resins and polyamide-based resins.
[4] The fiber-reinforced resin article according to [1], wherein the unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS) contain the same kind of resin.
[5] The fiber-reinforced resin article according to [1], which has a thickness of 0.1mm to 1.0 mm.
[6] The fiber-reinforced resin article according to [1], wherein the unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS) contain at least one fiber selected from the group consisting of carbon fibers and glass fibers.
[7] The fiber-reinforced resin article according to [1], wherein the surface on the side containing the Chopped Sheet (CS) has a resin sheet containing no reinforcing fibers.
[8]Such as [1]]The fiber-reinforced resin article is characterized in that the number of the Chopped Strands (CS) per unit area is 500-7000 pieces/m2。
[9] A method for producing a fiber-reinforced resin article, comprising:
disposing a plurality of unidirectional fiber-reinforced resin sheet material (CS) chopped strands, which are the same as or different from the unidirectional fiber-reinforced resin sheet material (UDS), on at least one surface of the unidirectional fiber-reinforced resin sheet material (UDS); and
and a step of heating and pressing the disposed article obtained in the disposing step.
[10] A laminate comprising the fiber-reinforced resin article according to [1] and a foam layer.
[11] The laminate according to [10], wherein the foam layer has a density of 0.2 to 0.7 g/cc.
[12] The laminate according to [10], wherein the fiber-reinforced resin article is located on one surface of the foam layer,
the surface of the fiber-reinforced resin article facing the foam layer side contains a plurality of Chopped Strands (CS).
[13] The laminate according to [10], wherein the fiber-reinforced resin article is located on one surface of the foam layer,
a unidirectional fiber reinforced resin sheet (UDS) is positioned on the other side of the foam layer,
the surface of the fiber-reinforced resin article facing the foam layer side contains a plurality of Chopped Strands (CS).
[14] The laminate according to [10], wherein the fiber-reinforced resin articles are each positioned on both surfaces of the foam layer,
the surface of each of the fiber-reinforced resin articles that faces the foam layer side contains a plurality of the Chopped Strands (CS).
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, it is possible to provide a fiber-reinforced resin article having a unique appearance with a marble pattern such as a random sheet and having no defects (for example, holes) even when the thickness is thin, a method for producing the same, and a laminate including the same.
In addition, the fiber-reinforced resin article of the present invention has improved strength (for example, tensile strength) in a direction other than the 0 ° direction (the direction parallel to the fiber direction of the unidirectional fiber-reinforced resin sheet) as compared with the unidirectional fiber-reinforced resin sheet.
Further, the fiber-reinforced resin article of the present invention is easier to satisfy the demand for reduction in thickness and weight than a random sheet or a laminate of a random sheet and a unidirectional fiber-reinforced resin sheet as described in patent document 2.
Further, by using the fiber-reinforced resin article for sheet insert molding or as a surface material when a foamed sheet or a honeycomb plate is processed into a laminate such as a sandwich panel, a lightweight and high-strength product can be provided.
Drawings
Fig. 1 is a schematic plan view showing one embodiment of a fiber-reinforced resin article of the present invention.
Fig. 2 is a photograph of a part of the appearance of the fiber-reinforced resin article obtained in example 1 taken from an oblique direction.
Fig. 3 is a photograph of a part of the appearance of the fiber-reinforced resin article obtained in comparative example 3 taken from an oblique direction.
Fig. 4 is a photograph of a part of the appearance of the fiber-reinforced resin article obtained in comparative example 4 taken from an oblique direction.
Detailed Description
< fiber-reinforced resin article >
Fig. 1 is a schematic plan view showing one embodiment of a fiber-reinforced resin article of the present invention. As shown in fig. 1, the fiber-reinforced resin article of the present invention is an article including a plurality of unidirectional fiber-reinforced resin sheet material Chopped Strands (CS)2 on at least one surface (sheet surface) of a unidirectional fiber-reinforced resin sheet material (UDS) 1.
The chopped strand sheet (CS)2 shown in fig. 1 is a small piece of the unidirectional fiber-reinforced resin sheet, and can be obtained by cutting the unidirectional fiber-reinforced resin sheet into small pieces, for example. The unidirectional fiber-reinforced resin sheet (CS)2 may be the same as or different from the unidirectional fiber-reinforced resin sheet (UDS) 1. Specific examples of the unidirectional fiber reinforced resin sheet (UDS)1 and the unidirectional fiber reinforced resin sheet that is a material of the chopped strand sheet (CS)2 will be described in detail later.
In the fiber-reinforced resin article shown in fig. 1, since a plurality of Chopped Strands (CS)2 are randomly dispersed and arranged on the surface thereof, the reflection of light rays is changed complicatedly by the irregularity of the orientation direction of the fibers, and a unique appearance of a marble pattern is formed. Since the Chopped Strands (CS)2 are integrated with the surface of the unidirectional fiber reinforced resin sheet (UDS)1, no holes are formed even if the Chopped Strands (CS)2 are not overlapped with each other. In addition, while the end faces of the Chopped Strands (CS) are likely to become starting points of breakage in the conventional random sheet, the fiber-reinforced resin article of the present invention is less likely to break because the proportion of the number of end faces of the Chopped Strands (CS)2 is small and the unidirectional fiber-reinforced resin sheet (UDS)1 is present. In addition, the chopped strand sheet (CS)2 is not likely to have extreme curling because the fiber direction is random.
The unidirectional fiber-reinforced resin sheet (UDS)1 shown in fig. 1 has high strength (for example, tensile strength) in the 0 ° direction (direction parallel to the fiber direction of the unidirectional fiber-reinforced resin sheet (UDS)), and the strength in the directions other than the 0 ° direction is improved by the chopped strand sheet (CS) 2. Thus, the fiber reinforced resin article of the present invention does not exhibit extreme local anisotropy. Thus, for example, even when a three-dimensional shape is imparted to a fiber-reinforced resin article by a molding method such as press molding or press molding, the fiber-reinforced resin article is less likely to be cracked and has excellent shape-following properties. Further, insert molding or secondary injection molding (overmolding) in which the fiber-reinforced resin article is inserted into an injection mold can be easily performed.
Unlike a laminate having a structure in which a random sheet obtained by molding a plurality of Chopped Strands (CS) into a sheet shape and a unidirectional fiber-reinforced resin sheet are laminated as described in patent document 2, the unidirectional fiber-reinforced resin sheet (UDS)1 shown in fig. 1 has a structure in which a plurality of Chopped Strands (CS)2 are contained in at least one surface (sheet surface) of the unidirectional fiber-reinforced resin sheet (UDS)1, and therefore, the requirements for reduction in thickness and weight are easily satisfied.
In the embodiment shown in fig. 1, the Chopped Strands (CS)2 are arranged so as not to overlap each other. In this case, it is preferable to arrange the fiber-reinforced resin articles so as not to overlap with each other as much as possible, for example, from the viewpoint of making the fiber-reinforced resin articles thin. However, the present invention is not limited thereto. Several of the plurality of Chopped Strands (CS)2 may be stacked on each other. The presence or absence of overlapping of the Chopped Strands (CS)2 and the number of layers thereof may be determined as appropriate depending on the target thickness of the fiber-reinforced resin article, for example.
In the embodiment shown in fig. 1, the unidirectional fiber reinforced resin sheet (UDS)1 includes a plurality of Chopped Strands (CS)2 on the entire one surface, but the present invention is not limited thereto. For example, the unidirectional fiber reinforced resin sheet (UDS)1 may include a plurality of Chopped Strands (CS)2 on both surfaces thereof, or may include a plurality of Chopped Strands (CS)2 only on one surface or a part of both surfaces thereof. In addition, a plurality of the Chopped Strands (CS)2 may be included on at least one surface of a laminate obtained by laminating a plurality of unidirectional fiber reinforced resin sheets (UDS) 1.
In the embodiment shown in fig. 1, the plurality of Chopped Strands (CS)2 are arranged to have a uniform size, but the present invention is not limited thereto. For example, 2 or more types of Chopped Strands (CS) having different sizes may be used, or the sizes may be distributed. The shape of the chopped strand sheet (CS) is not limited to the square shape, and may be other shapes.
In the embodiment shown in fig. 1, nothing is stacked on the surface of the side including the Chopped Strand (CS)2, but the present invention is not limited thereto. For example, the surface of the side including the Chopped Strand (CS)2 may have a resin sheet (protective film or the like) containing no reinforcing fibers. The resin sheet can protect the surface of a fiber-reinforced resin article, and can further improve the strength of a unidirectional fiber-reinforced resin sheet (UDS) in directions other than the 0 ° direction, reduce warpage during insert molding or secondary injection molding, and impart weather resistance and flame retardancy, for example. The resin sheet preferably contains the same kind of resin as the matrix resin of the unidirectional fiber reinforced resin sheet (UDS)1 and/or the matrix resin of the chopped strand sheet (CS) 2. In addition, additives such as weather resistance stabilizers and flame retardants may be contained. Such a resin sheet can be provided by, for example, heat lamination to the surface of the side including the Chopped Strand (CS) 2.
The proportion of the chopped strand sheet (CS) to 100 parts by mass of the unidirectional fiber-reinforced resin sheet (UDS) is 40 parts by mass or more and 100 parts by mass or less, and preferably 50 parts by mass or more and 90 parts by mass or less. When the amount of the chopped strand sheets (CS) is equal to or more than such a specific amount, it is preferable from the viewpoint of, for example, improving the strength of the unidirectional fiber-reinforced resin sheet (UDS) in directions other than the 0 ° direction and obtaining a unique appearance of a marble pattern. When the amount is equal to or less than the specific amount, it is preferable, for example, from the viewpoint of making the fiber-reinforced resin article thinner and lighter, from the viewpoint of improving the uniformity of the thickness of the fiber-reinforced resin article by reducing the overlapping portion between the Chopped Strands (CS) and reducing the variation in the number of layers at the overlapping portion, and from the viewpoint of reducing the number of portions (such as the end faces of the Chopped Strands (CS)) which are likely to become starting points of breakage.
The thickness of each of the unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS) is preferably 50 μm or more and 500 μm or less, and more preferably 100 μm or more and 250 μm or less. When the thickness is not less than the specific thickness, it is preferable, for example, to suppress the transmission of light and obtain a unique appearance of a marble pattern. When the thickness is not more than the specific thickness, it is preferable, for example, from the viewpoint of making the fiber-reinforced resin article thin and lightweight, from the viewpoint of improving the uniformity of the thickness of the fiber-reinforced resin article, and from the viewpoint of reducing the number of portions that serve as starting points for breakage.
The thickness of the fiber-reinforced resin article is preferably 0.1mm or more and 1.0mm or less, and more preferably 0.15mm or more and 0.5mm or less. When the thickness of the fiber-reinforced resin article is not less than the specific thickness, it is preferable from the viewpoint of processing a laminate such as a sandwich panel using the fiber-reinforced resin article as a surface material, for example, by insert injection molding of a sheet material suitable for using the fiber-reinforced resin article. When the thickness is not more than the specific thickness, it is preferable from the viewpoint of, for example, making the fiber-reinforced resin article thin and lightweight.
The unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS) each have a fiber volume fraction Vf of preferably 0.3 or more and 0.7 or less, and more preferably 0.35 or more and 0.6 or less. Specific methods for calculating the fiber volume fraction Vf are described in the later-described examples section.
The dimensions (length and width) of the unidirectional fiber-reinforced resin sheet (UDS) are not particularly limited, and may be determined as appropriate depending on the application for which the fiber-reinforced resin article is to be used. In general, the length thereof (length in a direction parallel to the fiber direction of the unidirectional fiber-reinforced resin sheet (UDS)) is preferably 10mm or more and 2000mm or less, and the width thereof (length in a direction perpendicular to the fiber direction of the unidirectional fiber-reinforced resin sheet (UDS)) is preferably 100mm or more and 600mm or less.
The width of the chopped strand sheet (CS) (the length in the direction perpendicular to the fiber direction of the chopped strand sheet (CS)) is preferably 3mm or more and 50mm or less, and more preferably 10mm or more and 25mm or less. When the width of the chopped strand sheet (CS) is made to be within such a specific range, it is preferable from the viewpoint of, for example, obtaining a unique appearance of a marble pattern.
The length of the Chopped Strand (CS) (the length in the direction parallel to the fiber direction of the Chopped Strand (CS)) is preferably 10mm or more and 50mm or less, and more preferably 10mm or more and 25mm or less. When the length of the chopped strand sheet (CS) is within such a specific range, it is preferable, for example, from the viewpoint of improving the strength of the unidirectional fiber reinforced resin sheet (UDS) in directions other than the 0 ° direction.
The aspect ratio (length/width) of the chopped strand sheet (CS) is preferably 0.5 or more and 5.0 or less, and more preferably 1.0 or more and 3.0 or less. In general, when the chopped strand sheet (CS) is press-molded, the following tendency is present: the Chopped Strands (CS) are not easily spread in the fiber direction but easily spread in a direction perpendicular to the fiber direction. Therefore, when the aspect ratio of the chopped strand sheet (CS) is within such a specific range, it is preferable, for example, from the viewpoint of appropriately suppressing the spreading of the sheet at the time of press molding.
The number of the Chopped Strands (CS) per unit area is preferably 500-7000 pieces/m2More preferably 700 to 7000 pieces/m2. When the number is equal to or greater than the above specific value, it is preferable from the viewpoint of, for example, improving the strength of the unidirectional fiber-reinforced resin sheet (UDS) in the direction other than the 0 ° direction and obtaining a unique appearance of a marble pattern. When the number is equal to or less than such a specific value, it is preferable, for example, from the viewpoint of making the fiber-reinforced resin article thinner and lighter, from the viewpoint of improving the uniformity of the thickness of the fiber-reinforced resin article by reducing the overlapping portions of the Chopped Strands (CS) and reducing the variation in the number of layers at the overlapping portions, and from the viewpoint of reducing the number of portions (such as the end faces of the Chopped Strands (CS)) which are likely to become starting points of breakage. The "unit area" in this number means a unit area of a plane parallel to the sheet surface of the unidirectional fiber reinforced resin sheet (UDS).
The plurality of Chopped Strands (CS) are preferably arranged so that the fiber directions thereof are random with each other. The higher the randomness of the arrangement, the more the marble-like unique appearance tends to be obtained, and the more the unidirectional fiber-reinforced resin sheet (UDS) tends to have a uniform degree of strength improvement in directions other than the 0 ° direction. The phrase "arranged in a random direction" means that: the fiber directions thereof do not coincide with a specific direction but are irregularly arranged.
The chopped strand sheets (CS) of the respective sizes described above can be obtained by cutting the unidirectional fiber reinforced resin sheet using a tool such as a cutter, scissors, guillotine cutter, or laser cutter.
In the present invention, the types of unidirectional fiber-reinforced resin sheet (UDS) and chopped strand sheet (CS) are not particularly limited, and known unidirectional fiber-reinforced resin sheet and chopped strand sheet can be used.
The unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS) preferably contain a thermoplastic resin, and more preferably contain at least one thermoplastic resin selected from the group consisting of polypropylene-based resins and polyamide-based resins, from the viewpoint of ease of integration by heat molding (e.g., press molding).
The unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS) preferably contain the same type of resin from the viewpoint of stability such as being not easily peeled off after integration. The resin is a resin generally contained as a matrix resin. Therefore, for example, when the unidirectional fiber-reinforced resin sheet (UDS) contains a polypropylene resin as a matrix resin, the chopped strand sheet (CS) preferably contains a polypropylene resin as a matrix resin, and when the unidirectional fiber-reinforced resin sheet (UDS) contains a polyamide resin as a matrix resin, the chopped strand sheet (CS) preferably contains a polyamide resin as a matrix resin.
The unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS) preferably contain at least one fiber selected from the group consisting of carbon fibers and glass fibers. In particular, in order to obtain a marble-like appearance, it is more preferable to contain carbon fibers.
< method for producing fiber-reinforced resin article >
The fiber-reinforced resin article of the present invention described above is not particularly limited in its production method. The method for producing a fiber-reinforced resin article of the present invention is a method for producing a fiber-reinforced resin article, comprising the steps of: disposing a plurality of unidirectional fiber-reinforced resin sheet material (CS) chopped strands, which are the same as or different from the unidirectional fiber-reinforced resin sheet material (UDS), on at least one surface of the unidirectional fiber-reinforced resin sheet material (UDS); and a step of heating and pressing the disposed article obtained in the disposing step.
In the step of arranging the plurality of Chopped Strands (CS), the Chopped Strands (CS) are preferably arranged so as not to overlap each other. However, the present invention is not limited thereto. As explained before, several of the plurality of Chopped Strands (CS) may be superimposed on each other. The presence or absence of overlapping of the Chopped Strands (CS) and the number of layers thereof may be determined as appropriate depending on, for example, the target thickness of the fiber-reinforced resin article. For example, a step of rearranging the chopped strand sheets (CS) may be provided simultaneously with or after the step of arranging a plurality of chopped strand sheets (CS) in order to reduce overlapping of the chopped strand sheets (CS).
In the step of arranging the plurality of Chopped Strands (CS), as described above, the plurality of Chopped Strands (CS) are preferably arranged so that the fiber directions thereof are random with each other. The higher the randomness of the arrangement, the more the marble-like unique appearance tends to be obtained, and the more the unidirectional fiber-reinforced resin sheet (UDS) tends to have a uniform degree of strength improvement in directions other than the 0 ° direction.
In the heating and pressing step, the heating temperature is preferably not lower than the melting point of the matrix resin used for the unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS). The heating temperature is usually 165 ℃ or higher and 250 ℃ or lower. The pressure is usually 0.5MPa or more and 5.0MPa or less.
The method for producing a fiber-reinforced resin article may further include: the fiber-reinforced resin article obtained through the heating and pressing step is provided with the resin sheet steps (for example, the heat lamination step and the bonding step) described above as necessary.
< fiber-reinforced resin composition >
The type of the fiber-reinforced resin composition constituting the unidirectional fiber-reinforced resin sheet (UDS) and the chopped strand sheet (CS) used in the present invention is not particularly limited. Specific examples thereof are described below.
The fiber-reinforced resin composition is generally a composition comprising reinforcing fibers (preferably reinforcing fiber bundles) and a matrix resin. The reinforcing fiber bundle can be obtained by treating reinforcing fibers with a sizing agent, for example. The fiber-reinforced resin composition can be obtained by aligning the reinforcing fiber bundles and bringing them into contact with, for example, a molten matrix resin.
As the reinforcing fiber, for example, high-strength and high-elastic modulus fibers such as carbon fibers, glass fibers, aramid fibers, alumina fibers, silicon carbide fibers, boron fibers, and metal fibers can be used. More than 2 kinds of them may be used in combination. The reinforcing fiber particularly preferably contains at least one fiber selected from the group consisting of carbon fiber and glass fiber. The average diameter of the monofilament is not particularly limited, but is preferably 1 to 20 μm, and more preferably 4 to 10 μm, from the viewpoint of mechanical properties and surface appearance. The number of filaments of the carbon fiber bundle is not particularly limited, but is preferably 100 to 100,000, more preferably 1,000 to 50,000, from the viewpoint of productivity and characteristics.
Examples of the sizing agent used for the reinforcing fiber bundles include modified polyolefins. The modified polyolefin is preferably a modified polyolefin comprising at least a metal salt of a carboxylic acid bonded to the polymer chain. Examples of the raw material of the modified polyolefin (unmodified polyolefin) include an ethylene polymer having a skeleton content derived from ethylene of more than 50 mol% and a propylene polymer having a skeleton content derived from propylene of more than 50 mol%. Specific examples of the ethylene polymer include ethylene homopolymers and copolymers of ethylene and an α -olefin having 3 to 10 carbon atoms. Specific examples of the propylene-based polymer include a propylene homopolymer and a copolymer of propylene and ethylene and/or an α -olefin having 4 to 10 carbon atoms. More specifically, homopolypropylene, homopolyethylene, ethylene-propylene copolymer, propylene-1-butene copolymer, and ethylene-propylene-1-butene copolymer are exemplified.
The modified polyolefin can be obtained, for example, by: a carboxylic acid group, a carboxylic acid anhydride group or a carboxylic acid ester group is introduced into the polymer chain of the unmodified polyolefin by grafting, and the group is converted into a state of a salt with a cation.
For example, the reinforcing fiber bundle treated with the sizing agent can be obtained by immersing the reinforcing fiber in an emulsion containing the sizing agent (and an additive such as an amine compound if necessary) and then drying the emulsion. The content of the sizing agent in the emulsion is preferably 0.001 mass% or more and 10 mass% or less. The amount of the sizing agent attached to the reinforcing fiber bundles is preferably 0.1 mass% or more and 5.0 mass% or less.
The fiber-reinforced resin composition can be obtained by aligning the reinforcing fiber bundles described above and bringing them into contact with, for example, a molten matrix resin. The type of the matrix resin is not limited, but a thermoplastic resin is preferable. Specific examples of the thermoplastic resin include thermoplastic resins such as polyolefin resins (for example, polypropylene resins and polyethylene resins), polyamide resins, polyester resins, polycarbonate resins, polyacetal resins, polyether ketone resins, polyether ether ketone resins, and polysulfone resins. In particular, the matrix resin more preferably contains at least one thermoplastic resin selected from the group consisting of polypropylene-based resins and polyamide-based resins. In addition, the matrix resin may contain a modified polyolefin.
< layered product >
The fiber-reinforced resin article of the present invention described above is preferably used as a laminate by being laminated with other articles. The type of the laminate is not particularly limited, and specifically, the laminate may be a sandwich panel obtained by laminating the fiber-reinforced resin article of the present invention on one or both surfaces of the foamed sheet or the honeycomb panel as described above, or may be another type of laminate.
The laminate of the present invention is a laminate comprising the fiber-reinforced resin article of the present invention and a foam layer. In this laminate, the fiber-reinforced resin article and the foam layer may be directly in contact with each other, or may be laminated via another layer (an intermediate layer or the like). A preferred embodiment is a laminate structure having a portion where the fiber-reinforced resin article is in contact with the foam layer. Further, at least one surface of the laminate is preferably a surface including a plurality of Chopped Strands (CS) (i.e., a surface having a marble-like appearance).
As one preferable embodiment of the laminate of the present invention, there is a laminate in which the fiber-reinforced resin article is located on one surface of the foam layer, and the surface of the fiber-reinforced resin article facing the foam layer side contains a plurality of Chopped Strands (CS). This embodiment is typically a laminate having a structure in which fiber-reinforced resin articles (CS/UDS)/foam layers are laminated in this order. In this embodiment, one surface of the foam layer is reinforced by the fiber-reinforced resin article, and the surface of the reinforced side of the laminate has a marble-like appearance.
As a preferred embodiment of the laminate of the present invention, there is a laminate in which the fiber-reinforced resin article is located on one surface of a foam layer, a unidirectional fiber-reinforced resin sheet (UDS) is located on the other surface of the foam layer, and the surface of the fiber-reinforced resin article opposite to the surface on the foam layer side contains a plurality of the Chopped Strands (CS). This embodiment is typically a laminate having a structure in which a fiber-reinforced resin article (CS/UDS)/a foam layer/a unidirectional fiber-reinforced resin sheet (UDS) are laminated in this order. In this embodiment, both surfaces of the foam body layer are reinforced by the fiber-reinforced resin article or the unidirectional fiber-reinforced resin sheet, and the surface of the laminate on the side having the chopped strand sheet (CS) has a marbled appearance.
Another preferred embodiment of the laminate of the present invention is a laminate in which the fiber-reinforced resin articles are located on both surfaces of the foam layer, and the surface of each fiber-reinforced resin article facing the foam layer side contains a plurality of Chopped Strands (CS). This embodiment is typically a laminate (sandwich panel) having a structure in which fiber-reinforced resin articles (CS/UDS)/foam layers/fiber-reinforced resin articles (UDS/CS) are laminated in this order. In this embodiment, both surfaces of the foam layer are reinforced by the fiber-reinforced resin article, and both reinforced surfaces of the laminate have a marble-like appearance.
In the laminate of the present invention, the resin contained in the foam layer (hereinafter referred to as "foam resin") is not particularly limited, and various known resins can be used, and the foam resin may be a crosslinked resin or a non-crosslinked one, and specific examples of the foam resin include thermoplastic resin foams such as polyethylene resin foams, polypropylene resin foams, polystyrene resin foams having a polypropylene resin foam in the outer layer, and particularly, the foam resin is preferably composed of the same kind of thermoplastic resin as the matrix resin contained in the fiber-reinforced resin article, and preferably both of the thermoplastic resin and the propylene resin, and the adhesive strength tends to be further improved by making such a structure, even if the base resin contains a polypropylene-based resin and the foam layer contains a polybutylene-based resin, both of them contain a polyolefin-based resin, and therefore the base resin and the foam layer contain "the same kind of thermoplastic resin". Examples of the resin include, in addition to polyolefin resins, polycarbonate resins, styrene resins, polyester resins, polyphenylene sulfide resins (PPS resins), modified polyphenylene ether resins (modified PPE resins), polyacetal resins (POM resins), liquid crystal polyesters, polyarylates, acrylic resins such as polymethyl methacrylate resins (PMMA), vinyl chloride, Polyimide (PI), Polyamideimide (PAI), polyether imide (PEI), polysulfone, polyethersulfone, polyketone, polyetherketone, Polyetheretherketone (PEEK), modified polyolefins, phenol resins, phenoxy resins, and polyamide resins. Further, "both are propylene-based resins" means: both the matrix resin and the foam layer contain a polymer containing 50 mass% or more of propylene as a structural unit.
The density of the foam layer is preferably 0.2 to 0.7g/cc, more preferably 0.25 to 0.4 g/cc. The cells in the foam resin may be closed cells or interconnected cells. In general, the strength of the closed-cell foam resin tends to be high.
The foaming ratio of the foam layer is preferably 1.3 to 5 times, and more preferably 2 to 4 times.
The foam layer may include a rib structure, and more specifically, may include a non-foam rib structure in a portion of the foam layer. The rib structure functions to suppress shrinkage and deformation of the foam, for example. The form of the rib structure is not particularly limited, and may be, for example, a lattice form, a stripe form, a cylindrical form, a ring form, or the like. These shapes may take a form of overlapping each other. The rib structure may be such that ribs having a cross-sectional direction of a lattice shape or the like are formed on the entire front and back surfaces of the foam layer, or may be such that ribs having a cross-sectional direction of a lattice shape or the like are formed on the entire front or part of the front or back surface. In addition, the structures on the front side and the structures on the back side can be connected. As a method of forming a non-foamed rib structure in a part of the foam layer, for example, there is a method of bringing a part of the foam layer into contact with a heated knife to thermally melt a desired position. Further, the following methods can be mentioned: a method of pressing a heated rod-shaped metal against the foam layer to form a columnar shape; a method of pressing the heated tubular metal against the foam layer to form an annular shape.
The thickness of the laminate of the present invention (including the thickness of the entire fiber-reinforced resin article and foam layer) is preferably 2 to 16mm, and more preferably 2 to 10 mm.
The method for producing the laminate of the present invention is not particularly limited. For example, the layers may be sequentially stacked and used as a laminate as they are, part or all of the interfaces of the layers may be bonded using an adhesive, or part or all of the interfaces of the layers may be fused by applying pressure and heat using a device such as a press or a soldering iron. The end portions of the respective layers may be fixed by an adhesive tape, or may be inserted into any portion of the respective layers so as not to be positionally displaced by a resin pin. In particular, a method of applying pressure and heat to weld a part or all of the interfaces of the respective layers is preferable.
The laminate of the present invention may be a laminate having a three-dimensional shape. The specific form of the three-dimensional shape is not particularly limited, and a surface thereof is given a shape other than a planar shape. Specific examples of the method for imparting a three-dimensional shape include a hot press method (e.g., heat and cool method, press method) and a vacuum forming method. The laminate of the present invention is less likely to cause defects in appearance such as cracks when a three-dimensional shape is imparted by a processing method such as hot pressing, as compared with a conventional laminate in which a foam sheet is reinforced with only unidirectional fiber-reinforced resin sheets.
The fiber-reinforced resin article and the laminate including the same of the present invention can be suitably used in various fields. In particular, the present invention is useful for applications requiring lightweight and high strength articles such as electric parts, PC cases, mobile phone cases, automobile parts, furniture, partitions, curtain walls (screen walls), doors, and sliding doors. In addition, the present invention is also useful for applications requiring designability, such as wall paper, flooring material, and decorative sheet for building materials.
Examples
The present invention will be described in more detail below with reference to examples. However, the present invention is not limited thereto. The evaluation methods used in the examples are as follows.
< tensile test >
The tensile strength was measured at 23 ℃ at a tensile rate of 0.45 mm/min using a tensile tester AG-X100 kN manufactured by Shimadzu corporation. Tensile test was conducted under the conditions in accordance with JIS K7164 except for the thickness of the test piece, and Young's modulus and tensile strength were measured.
< sheet thickness >
The thickness was measured using a digital display standard outside micrometer MDE-MX manufactured by Mitutoyo corporation at 3 points per 1 side of the sample and at 8 points in total (1 point in 2 adjacent sides in common).
< fiber volume fraction Vf >
A sheet of the sample was cut in a square of 50mm X50 mm, and the mass wc (g) was measured. The cut sample was heated at 480 ℃ for 1 hour to thermally degrade the resin and remove it, and the mass wf (g) of the carbon fiber alone was measured to determine the fiber volume fraction Vf using the following equation.
Fiber volume fraction Vf ═ (Wf/Wc) × ρ c/ρ f
Here,. rho.c is the density (g/cm) of the sample3) And ρ f is the density (g/cm) of the carbon fiber used in the sample3)。
< example 1>
(preparation of unidirectional fiber-reinforced resin sheet (UDS))
A unidirectional fiber-reinforced resin sheet (of which the thickness was 162.4 μm and the fiber volume fraction Vf was 0.53) was produced by the method described in example 6 of international publication No. 2016/114352, and cut out to obtain a unidirectional fiber-reinforced resin sheet (UDS) of 200mm × 200 mm. The mass of the unidirectional fiber-reinforced resin sheet (UDS) was 8.98 g.
(production of chopped strand sheet (CS))
The unidirectional fiber-reinforced resin sheet (UDS) similar to the unidirectional fiber-reinforced resin sheet (UDS) produced as described above was slit into a tape shape with a width of 12.5mm, and further cut into a length of about 15mm to obtain a plurality of Chopped Sheets (CS).
(production of fiber-reinforced resin article)
The plurality of Chopped Strands (CS)4.49g produced as described above were randomly arranged on the unidirectional fiber-reinforced resin sheet (UDS) so as to be as non-overlapping as possible (the proportion of Chopped Strands (CS) to 100 parts by mass of the unidirectional fiber-reinforced resin sheet (UDS) was 50 parts by mass, and the number of Chopped Strands (CS) per unit area was about 3200 pieces/m2). Next, the unidirectional fiber reinforced resin sheet (UDS) was sandwiched between 2 stainless steel plates, and a pressure of 2MPa was applied for 3 minutes using a press (MINI TEST PRESSMP-WCH, manufactured by toyoyo seiki) heated to 185 ℃. Thereafter, the plate was moved to a pressurizing device adjusted to 15 ℃ and cooled by applying a pressure of 2MPa for 30 seconds and a pressure of 4MPa for 30 seconds. By such press molding, a smooth fiber-reinforced resin article having a thickness of 255 μm was obtained. The total mass of the fiber-reinforced resin article was 13.47g, and the total mass of the fiber-reinforced resin article was relative to the unidirectional fibersThe ratio of the mass of the reinforced resin sheet (UDS) (hereinafter referred to as "mass ratio") was 1.5.
Tensile tests were conducted on the fiber-reinforced resin article in the 0 ° direction, 45 ° direction, and 90 ° direction, and the young's modulus and tensile strength were measured. Here, the 0 ° direction is a direction parallel to the fiber direction of the unidirectional fiber reinforced resin sheet (UDS), the 45 ° direction is a direction at 45 ° to the fiber direction, and the 90 ° direction is a direction at right angles to the fiber direction. The size of each test piece was set to 25mm × 150 mm. As a result, the young's modulus in the 0 ° direction of the fiber-reinforced resin article was 61.53GPa, the tensile strength was 587MPa, the young's modulus in the 45 ° direction was 5.44GPa, the tensile strength was 10.9MPa, the young's modulus in the 90 ° direction was 4.05GPa, and the tensile strength was 9.0 MPa. The Chopped Strand (CS) side of the fiber-reinforced resin article has a marble-like appearance. Fig. 2 is a photograph of a part of the external appearance of the mobile terminal taken from an oblique direction.
< example 2>
A smooth fiber-reinforced resin article was produced in the same manner as in example 1, except that the mass of the chopped strand sheets (CS) disposed on the unidirectional fiber-reinforced resin sheet (UDS) was changed to 5.39g, and a tensile test was performed (the proportion of the chopped strand sheets (CS) to 100 parts by mass of the unidirectional fiber-reinforced resin sheet (UDS) was 60 parts by mass, and the number of the chopped strand sheets (CS) per unit area was about 3840 pieces/m2). The fiber-reinforced resin article had a thickness of 251 μm, a total mass of 14.37g, and a mass ratio of 1.6. The young's modulus in the 0 ° direction of the fiber-reinforced resin article was 69.64GPa, the tensile strength was 609MPa, the young's modulus in the 45 ° direction was 6.53GPa, the tensile strength was 13.1MPa, the young's modulus in the 90 ° direction was 5.42GPa, and the tensile strength was 7.9 MPa. The chopped strand sheet (CS) side of the fiber-reinforced resin article has a marble-like appearance.
< example 3>
A smooth fiber-reinforced resin article was produced in the same manner as in example 1, except that the mass of the chopped strand sheet (CS) disposed on the unidirectional fiber-reinforced resin sheet (UDS) was changed to 8.08g, and a tensile test was performed (with respect to the mass of the chopped strand sheet (CS) disposed on the unidirectional fiber-reinforced resin sheet (UDS))The proportion of the chopped strand sheets (CS) per 100 parts by mass of the unidirectional fiber-reinforced resin sheet (UDS) was 90 parts by mass, and the number of the chopped strand sheets (CS) per unit area was about 5760 pieces/m2). The fiber-reinforced resin article had a thickness of 313 μm, a total mass of 17.06g, and a mass ratio of 1.9. The young's modulus in the 0 ° direction of the fiber-reinforced resin article was 64.94GPa, the tensile strength was 588MPa, the young's modulus in the 45 ° direction was 22.7GPa, the tensile strength was 24.3MPa, the young's modulus in the 90 ° direction was 4.72GPa, and the tensile strength was 11.3 MPa. The chopped strand sheet (CS) side of the fiber-reinforced resin article has a marble-like appearance.
< comparative example 1>
2 unidirectional fiber-reinforced resin sheets (UDS) similar to the unidirectional fiber-reinforced resin sheet produced in example 1 were stacked in the 0 ° direction, and press-molded under the same conditions as in example 1 to obtain a smooth fiber-reinforced resin article having a thickness of 323 μm. The total mass of the fiber-reinforced resin article was 17.96g, and the mass ratio was 2.0. The mass ratio in comparative example 1 is a ratio of the total mass of the fiber-reinforced resin article to the mass of the unidirectional fiber-reinforced resin sheet (UDS) serving as the base. The tensile test was carried out in the same manner as in example 1, and as a result, the young's modulus in the 0 ° direction was 105.42GPa, the tensile strength was 1499MPa, the young's modulus in the 45 ° direction was 5.03GPa, the tensile strength was 9.3MPa, the young's modulus in the 90 ° direction was 3.43GPa, and the tensile strength was 5.6MPa, and the strengths in the 45 ° direction and the 90 ° direction were lower than those of the fiber-reinforced resin article of example 1. In addition, in the unidirectional fiber-reinforced resin article of comparative example 1, when a three-dimensional shape is imparted by press molding, the possibility of occurrence of cracks is high.
< comparative example 2>
A unidirectional fiber-reinforced resin sheet (UDS) having a thickness of 314 μm was laminated so that 1 sheet was oriented at 0 ° and the other 1 sheet was oriented at 90 ° in the same manner as the unidirectional fiber-reinforced resin sheet prepared in example 1, and press-molded under the same conditions as in example 1 to obtain a fiber-reinforced resin article having a thickness of 314 μm. The total mass of the fiber-reinforced resin article was 17.96g, and the mass ratio was 2.0. The mass ratio in comparative example 2 is a ratio of the total mass of the fiber-reinforced resin article to the mass of the unidirectional fiber-reinforced resin sheet (UDS) serving as the base. The obtained fiber-reinforced resin article was greatly curled due to the difference in shrinkage rates between the 0 ° direction and the 90 ° direction. The tensile test was carried out in the same manner as in example 1, and as a result, the young's modulus in the 0 ° direction (the direction parallel to the fiber direction of the lower unidirectional fiber-reinforced resin sheet (UDS)) was 57.84GPa, the tensile strength was 699MPa, the young's modulus in the 45 ° direction was 4.92GPa, the tensile strength was 36.5MPa, and the young's modulus in the 90 ° direction (the direction perpendicular to the fiber direction of the lower unidirectional fiber-reinforced resin sheet (UDS)) was 50.0GPa and the tensile strength was 604 MPa. Further, the bidirectional (0 ° and 90 ° directions) fiber-reinforced resin article as in comparative example 2 has poor shape-following properties, and when a three-dimensional shape is imparted by press molding, cracks or wrinkles may occur.
< comparative example 3>
A fiber-reinforced resin article was produced in the same manner as in example 1, except that the mass of the Chopped Strands (CS) disposed on the unidirectional fiber-reinforced resin sheet (UDS) was changed to 2.70g, and a tensile test was performed (the proportion of the Chopped Strands (CS) to 100 parts by mass of the unidirectional fiber-reinforced resin sheet (UDS) was 30 parts by mass, and the number of the Chopped Strands (CS) per unit area was about 1920 pieces/m2). The thickness of the fiber-reinforced resin article was 210. mu.m, the total mass was 11.67g, and the mass ratio was 1.3. The Young's modulus in the 0 ° direction of the fiber-reinforced resin article was 58.50GPa, the tensile strength was 516MPa, the Young's modulus in the 45 ° direction was 4.70GPa, the tensile strength was 8.2MPa, the Young's modulus in the 90 ° direction was 2.78GPa, and the tensile strength was 4.5MPa, which are inferior to those of the examples. In addition, the chopped strand sheet (CS) side of the fiber-reinforced resin article has large gaps in appearance, and is in a mottled state, which cannot be said to be a marble pattern. Fig. 3 is a photograph of a part of the external appearance of the mobile terminal taken from an oblique direction.
< comparative example 4>
On a stainless steel plate, 17.96g of a plurality of Chopped Strands (CS) identical to the chopped strand produced in example 1 were randomly arranged within a size of 200mm × 200mm so as to form as few as possible an overlap of more than 2 layers, and press-molded under the same conditions as in example 1 to obtain a fiber-reinforced resin article (random sheet) having a thickness of 321 μm. However, pores are generated in various portions of the fiber-reinforced resin article, and a uniform sheet is not obtained. Fig. 4 is a photograph of a part of the external appearance of the mobile terminal taken from an oblique direction.
The results of examples 1 to 3 and comparative examples 1 to 4 are summarized in Table 1.
[ Table 1]
TABLE 1
Figure BDA0003263385740000201
< example 4>
(production of fiber-reinforced resin article)
2 pieces of the same fiber-reinforced resin article having a thickness of 255 μm as in example 1 were produced.
(preparation of laminate)
A foamed sheet of polypropylene having a thickness of 5mm (manufactured by Mitsui Chemicals Tohcello, Inc., trade name of PAULOWNIA, density of 0.3g/cc, expansion ratio of 3 times) was cut out in a shape of 200mm × 200 mm. Then, the fiber reinforced resin article/foamed sheet/fiber reinforced resin article are laminated in this order. In the laminating step, the surface (inner surface) of each fiber-reinforced resin article that is in contact with the foam sheet is the surface of the unidirectional fiber-reinforced resin sheet (UDS), and the surface (outer surface) that faces this surface is the surface on the chopped strand sheet (CS) side. The unidirectional fiber-reinforced resin sheet (UDS) of each fiber-reinforced resin article was oriented in the same direction (0 ° direction).
Then, a release film was placed on the outer surface of each fiber-reinforced resin article, and the release film was loaded into a press (manufactured by Toyo Seiki Seisaku-Sho Ltd., device name MINI TEST PRESS MP-WCL) heated to 200 ℃ and pressed under a pressure of 0.8MPa for 1 minute. Then, the resultant was transferred to a pressure device (manufactured by Toyo Seiki Seisaku-Sho Ltd., product name: MINI TEST PRESS MP-WC) cooled with 40 ℃ cooling water, and cooled under a pressure of 0.2MPa for 10 minutes. Then, the release film was removed and peeled off to obtain a laminate (sandwich) having a thickness of 5mm and a laminate structure of a fiber-reinforced resin article (CS/UDS)/a foam layer/a fiber-reinforced resin article (UDS/CS). The two outer side surfaces of the laminate are surfaces on the Chopped Strand (CS) side of the fiber-reinforced resin article, and the appearance thereof is in a marble pattern.
Industrial applicability
The fiber-reinforced resin article of the present invention can be suitably utilized in various fields. In particular, the present invention is useful for applications requiring lightweight and high strength articles such as electric parts, PC cases, mobile phone covers, automobile parts, furniture, partitions, curtain walls, doors, and sliding doors. In addition, the present invention is also useful for applications requiring designability, such as wall paper, flooring material, and decorative sheet for building materials.
Description of the reference numerals
1 unidirectional fiber reinforced resin sheet (UDS)
2 chopped strand sheets (CS)

Claims (14)

1. A fiber-reinforced resin article comprising a plurality of unidirectional fiber-reinforced resin sheets (CS) that are the same as or different from unidirectional fiber-reinforced resin sheets (UDS) on at least one side of the unidirectional fiber-reinforced resin sheets (UDS),
the proportion of the chopped strand sheet (CS) is 40 to 100 parts by mass with respect to 100 parts by mass of the unidirectional fiber-reinforced resin sheet (UDS).
2. The fiber reinforced resin article according to claim 1, wherein the unidirectional fiber reinforced resin sheet (UDS) and the Chopped Sheet (CS) comprise a thermoplastic resin.
3. The fiber reinforced resin article according to claim 2, wherein the thermoplastic resin is at least one thermoplastic resin selected from the group consisting of polypropylene-based resins and polyamide-based resins.
4. The fiber reinforced resin article according to claim 1, wherein the unidirectional fiber reinforced resin sheet (UDS) and the Chopped Sheet (CS) contain the same kind of resin.
5. The fiber-reinforced resin article according to claim 1, having a thickness of 0.1mm or more and 1.0mm or less.
6. The fiber reinforced resin article according to claim 1, wherein the unidirectional fiber reinforced resin sheet (UDS) and the Chopped Sheet (CS) contain at least one fiber selected from the group consisting of carbon fibers and glass fibers.
7. The fiber reinforced resin article according to claim 1, wherein a surface on a side containing the Chopped Sheet (CS) has a resin sheet containing no reinforcing fibers.
8. The fiber reinforced resin article according to claim 1, wherein the number of the Chopped Strands (CS) per unit area is 500 to 7000 pieces/m2。
9. A method for producing a fiber-reinforced resin article, comprising:
disposing a plurality of unidirectional fiber-reinforced resin sheet material (CS) chopped strands, which are the same as or different from the unidirectional fiber-reinforced resin sheet material (UDS), on at least one surface of the unidirectional fiber-reinforced resin sheet material (UDS); and
and a step of heating and pressing the disposed article obtained in the disposing step.
10. A laminate comprising the fiber-reinforced resin article according to claim 1 and a foam layer.
11. The laminate according to claim 10, wherein the foam layer has a density of 0.2 to 0.7 g/cc.
12. The laminate according to claim 10, wherein the fiber reinforced resin article is located on one face of the foam layer,
the surface of the fiber-reinforced resin article that faces the foam layer side contains a plurality of Chopped Strands (CS).
13. The laminate according to claim 10, wherein the fiber reinforced resin article is located on one face of the foam layer,
a unidirectional fiber reinforced resin sheet (UDS) is located on the other face of the foam layer,
the surface of the fiber-reinforced resin article that faces the foam layer side contains a plurality of Chopped Strands (CS).
14. The laminate according to claim 10, wherein the fiber reinforced resin articles are each located on both faces of the foam layer,
the surface of each of the fiber-reinforced resin articles that faces the foam layer side contains a plurality of the Chopped Strands (CS).
CN202080021468.2A 2019-03-19 2020-03-04 Fiber-reinforced resin article, method for producing same, and laminate comprising same Pending CN113573864A (en)

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